Radiant heating or cooling panel

ABSTRACT

A panel for use with systems for heating and/or cooling an enclosed space by circulating a fluid through a closed tubing arrangement, is provided. The inventive radiant heating or cooling panel, which is made up of a radiant heat transfer or cooling plate having a length, and an elongated C-shaped or side opening receptacle that extends along the length of the plate for receiving tubing, facilitates tubing installation, while minimizing the danger of tubing popping out or disengaging from the panel after installation. In a preferred embodiment, the inventive panel demonstrates greater radiant heat dissipation and cooling capacity and efficiency.

RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 60/687,701, filed Jun. 6, 2005.

TECHNICAL FIELD OF THE INVENTION

The present invention generally relates to a panel for use with heatingand cooling systems, and more particularly relates to a panel for usewith systems for heating and/or cooling an enclosed space by circulatinga fluid through a closed tubing arrangement. The inventive panelfacilitates tubing installation, while minimizing the danger of tubingpopping out or disengaging from the panel after installation. Theinventive panel, in a preferred embodiment, demonstrates greater radiantheat dissipation and cooling capacity and efficiency.

BACKGROUND OF THE INVENTION

Radiant floor heating has been used for hundreds of years. The Romanswere known to channel hot air under the floors of their villas, whilethe Koreans were known to channel hot flue gases under their floorsbefore venting them up the chimney. In the 1930s, Frank Lloyd Wrightdesigned many of his buildings with radiant floor heating.

There are three basic types of radiant floor heat, namely, radiant airfloors where air is the heat carrying medium, electric radiant floors,and hydronic (liquid or hot water) radiant floors. All three types canbe further subdivided by the type of installation: “wet”installations—those that make use of the large thermal mass of aconcrete slab floor or lightweight concrete over a wooden subfloor, and“dry” installations—those in which the installer inserts the radiantfloor tubing between two layers of plywood or attaches the tubing underthe finished or subfloor.

Hydronic (liquid or hot water) radiant floor systems, which have beendeemed the most popular and cost-effective systems for heating-dominatedclimates, pump heated liquid or water from a boiler through tubing laidin a pattern underneath the floor. The temperature in each room iscontrolled by regulating the flow of hot liquid or water through eachtubing loop. This is done by a system of zoning valves or pumps andthermostats.

In terms of installation, dry floor installations have been gainingpopularity over wet floor installations. This is due in part to the factthat dry floors are faster and less expensive to build.

As alluded to above, dry radiant floors may be prepared or fabricated byinstalling the tubing from above the floor, between two layers ofsubfloor. In these instances, the tubes are often in aluminum diffusersthat spread the liquid or water's heat across the floor in order to heatthe floor more evenly. The tubing and heat diffusers may be securedbetween furring strips (sleepers) which carry the weight of the newsubfloor and finished floor surface.

Several companies have attempted to improve upon the heat diffusers usedin dry installations. For example, U.S. Pat. No. 5,454,428 to Pickard etal. (the '428 patent) discloses an extruded aluminum radiant heattransfer plate having heat transfer side edges or fins and an elongatedreceptacle running the length of the extrusion for receiving andholding/confining plastic tubing. The elongated receptacle can take theform of a “C” that stands above the plane of the heat transfer fins, orthe form of a “U”, the legs of which integrally connect to the fins.

As referenced in Cols. 1 to 2, lines 63 to 4, of the '428 patent, ineither of the above-referenced configurations, the tubing-receivingchannel is semicircular with the degree of wrap being on the order of200° . The sides of the receptacle that lead into the channel are planarand acutely-sloped from the vertical at about 30° . The sloped sides ofthe receptacle serve as a guideway facilitating the positioning andinsertion of the tubing into the channel.

The inner diameter of the tubing-receiving channel closely approximatesthe outer diameter of the plastic tubing. Moreover, the tubing-receivingchannel is extruded to a thickness that prevents it from readilydeforming. As such, the plastic tubing is reportedly deformed duringinsertion and held tightly within the receiving channel permitting heattransfer essentially by conduction.

The side fins are relatively thin-walled (e.g., 0.078 to 0.015 inches),while the thickness of the walls of the tubing receptacle are relativelythick (e.g., at least 0.060 inches). See Col. 3, lines 44 to 50, andCol. 5, lines 9 to 13, of the '428 patent.

The principal mode of heat transfer between the tubing and the channelwall in the '428 patent is one of conductance and not convection. SeeCol. 5, lines 44 to 47, of the '428 patent. This reference teaches thatheat transfer by way of convection will result in deterioration of theheat transfer characteristics of the system. See Col. 5, lines 26 to 31,of the '428 patent.

U.S. Pat. No. 5,743,330 (the '330 patent) discloses panels forsupporting heat transfer tubing that are touted as improvements over thehydronic radiant heat distribution panel and system of the '428 patent.The inventive panels basically comprise a track for receiving tubingcarrying heat transfer fluid, which has an inner surface that ismulti-faceted. The term “multi-faceted” is defined at Col. 3, lines 21to 24, of the '330 patent as being “composed of a series ofdiscontinuous, discrete, substantially straight faces 90 that are angledwith respect to one another (FIGS. 1A and 2A).”

The segmented faces 90 of the multi-faceted, inner surface reportedlyserve to securely grip the heat transfer tubing 17, thereby minimizingdanger of the tubing 17 popping out or disengaging from the track 2after installation, while providing for both convective and conductiveheat transfer between the tubing 17 and receiving panel 1.

U.S. Patent Appl. Serial No. US 2005/0028966 A1 (the '966 patentapplication) discloses an improved heat distribution panel whichutilizes an extruded tubing receptacle having a tube receiving channelfor tightly gripping heat tubing throughout both straight and curved orlooped runs. The tubing receptacle has a generally square or rectangularperipheral outline, which includes flat side wall and flat bottomsurfaces. Heat tubing is received and retained by a snap-fit in the tubereceiving channel of the tubing receptacle for heat transfer directly tothe tubing receptacle essentially by conduction rather than convection.See page 1, paragraph [0008], of the '966 patent application. Thechannel portion of the receptacle may be constructed in accordance withthe teachings of U.S. Pat. No. 5,454,428. See page 3, paragraph [0026],of the '966 patent application. Sheet metal heat transfer plates may beheld against or permanently attached to the essentially planar outsidesurfaces of the tubing receptacle.

Unfortunately, tubing installed with the heat transfer plates or panelsdescribed above, which all employ top opening tubing receptacles forholding/confining plastic tubing, have been known to pop out ordisengage from the receptacle after installation due to expansion andcontraction of the tubing as liquid or water flowing there throughchanges temperature. Gravitational forces and/or vibrational stressencountered by the panels during system operation further promote thistendency of the tubing to disengage.

It is therefore a stated object of the present invention to address thisdeficiency and, in a preferred embodiment, to improve upon the radiantheat dissipation and cooling capacity and efficiency demonstrated byprior art radiant panels.

SUMMARY

The present invention therefore provides a radiant heating or coolingpanel that basically comprises: a radiant heat transfer or cooling platehaving a length; and an elongated C-shaped or side opening receptaclefor receiving tubing (e.g., plastic tubing), where the elongatedC-shaped receptacle extends along the length of the radiant heattransfer or cooling plate and is formed from upper and lower arcuate orangled sections, and where the lower arcuate or angled section of theC-shaped receptacle is fixably attached to the plate along the length ofthe plate.

In one contemplated embodiment, a plurality of depressions extend alongan inner surface of the elongated tubing receptacle, preferablyextending along that portion of the inner surface of the tubingreceptacle that interfaces (i.e., forms a common boundary) with theradiant heat transfer or cooling plate.

In a more preferred embodiment, the plurality of depressions take theform of either discontinuous depressions or continuous depressions thateach extend along the entire length of the inner surface of the lowerarcuate or angled section of the C-shaped receptacle, where eachcontinuous depression is contiguous to at least one other continuousdepression.

Other features and advantages of the invention will be apparent to oneof ordinary skill from the following detailed description andaccompanying drawings.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. All publications, patentapplications, patents and other references mentioned herein areincorporated by reference in their entirety. In case of conflict, thepresent specification, including definitions, will control. In addition,the materials, methods, and examples are illustrative only and notintended to be limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Particular features of the disclosed invention are illustrated byreference to the accompanying drawings in which:

FIG. 1 is a cross-sectional side view of a preferred embodiment of theradiant heating or cooling panel of the present invention; and

FIG. 2 is a partially sectioned perspective view of the inventiveradiant heating or cooling panel shown in FIG. 1.

BEST MODE FOR CARRYING OUT THE INVENTION

Although the present inventive radiant heating or cooling panel isdescribed herein mainly in conjunction with radiant floor heatingsystems, it is not so limited. The inventive panel may be used with anysystem for heating and/or cooling an enclosed space by circulating afluid through a closed tubing arrangement. More specifically, theinventive panel may be used in a radiant heating system or in a coolingsystem where a thermal medium is circulated that transmits heat to theradiant heating panels or that receives heat from the cooling panels.

The C-shaped or side-opening tubing receptacle of the inventive panelfacilitates tubing installation, making it easier for an installer toinsert tubing along the length of the panel while minimizing the dangerof the tubing popping out or disengaging from the receptacle afterinstallation due to expansion and contraction of the tubing as liquid orwater flowing there through changes temperature. Gravitational forcesand/or vibrational stress encountered by the panels during systemoperation further promote this tendency of the tubing to disengage.

In addition to that noted above, and in a preferred embodiment of thepresent invention, heat transfer is increased by providing a pluralityof depressions in the inner surface of the tubing receptacle. In a morepreferred embodiment, the depressions are located in that portion of theinner surface of the tubing receptacle that interfaces with the radiantheat transfer or cooling plate. The depressions serve to increase thesurface area for convective and conductive heat transfer to the radiantheat transfer or cooling plate, thereby providing the inventive panelwith greater heat dissipation and/or cooling capacity and efficiency.

Referring now to the drawings in detail, a preferred embodiment of theradiant heating or cooling panel of the present invention is shown andgenerally designated by reference numeral 10.

As best shown in FIG. 1, the preferred embodiment of the inventiveradiant heating or cooling panel 10 basically comprises: a radiant heattransfer or cooling plate 12 having a length; and an elongated C-shapedor side opening receptacle 14 having upper and lower arcuate or angledsections 16 a, 16 b, that extends along the length of the radiant heattransfer or cooling plate 12 for receiving tubing (e.g., plastictubing), wherein a plurality of depressions 18 a, 18 b, 18 c, extendalong a portion 20 of an inner surface of the lower section 16 b of theelongated tubing receptacle 14 that interfaces (i.e., forms a commonboundary) with plate 12.

The radiant heat transfer or cooling plate 12 is a planar structure thatserves to transfer heat to (or from) surrounding areas and preferablycomprises mounting means such as pre-punched mounting holes. While thesize and shape of plate 12 is not limited, it is preferred that plate 12adopt a rectangular configuration. It is further preferred that thelength of plate 12 range from about 0.9 to about 1.5 meters (m) (morepreferably, from about 1.1 to about 1.3 m), that the width of plate 12range from about 5.1 to about 15.2 centimeters (cm) (more preferably,from about 7.6 to about 12.7 cm) and that the thickness of plate 12range from about 0.25 to about 1.78 millimeters (mm)(more preferably,from about 0.51 to about 1.52 mm).

As noted above, the elongated C-shaped or side opening receptacle 14 hasupper and lower arcuate or angled sections 16 a, 16 b, and extends alongthe length of plate 12. A plurality of depressions 18 extend along aninner surface of the lower section 16 b of the elongated tubingreceptacle 14, preferably located on portion 20 of the inner surfacethat interfaces with plate 12.

The channel defined by tubing receptacle 14 is preferably semicircularin cross-section, having a diameter that closely approximates the outerdiameter of the tubing (as specified in, for example, ASTM F-876), and apreferred thickness that ranges from about 0.25 to about 1.78 mm (morepreferably, from about 0.51 to about 1.52 mm). The channel defined bytubing receptacle 14 may also adopt a square or rectangularcross-sectional shape. In yet a more preferred embodiment, the thicknessof receptacle 14 is similar, if not identical, to the thickness of plate12. The degree of wrap of tubing receptacle 14 is greater than about190° (preferably, from about 220° to about 260° ).

Depressions 18 may take the form of discontinuous depressions (i.e.,depressions that do not each extend along the entire length of the innersurface of tubing receptacle 14), or continuous, adjacent or contiguousdepressions (i.e., depressions that extend along the entire length ofthe inner surface of tubing receptacle 14 and that are contiguous to (ortouch) at least one other continuous depression). The size and shape ofthe depressions 18 are not limited. In a preferred embodiment,depressions 18 are contiguous U-shaped depressions or valleys thatextend along the entire length of the tubing receptacle 14, and thateach have a width ranging from about 0.13 to about 0.38 mm (preferably,from about 0.18 to about 0.33 mm), and a depth ranging from about 0.25to about 0.76 mm (preferably, from about 0.38 to about 0.64 mm).

In the preferred embodiment of panel 10 shown in FIGS. 1 and 2, tubingreceptacle 14 is provided with flared edges 22 a, 22 b, and contiguous,U-shaped depressions or valleys 18 a, 18 b, 18 c formed in a portion 20of the inner surface of the lower section 16 b of tubing receptacle 14,that extend along the entire length of receptacle 14.

Plate 12 and flared edges 22 a, 22 b, each aid in the positioning oftubing prior to insertion into tubing receptacle 14. Moreover, uponinsertion of the tubing into receptacle 14, the side opening inreceptacle 14 aids in preventing the tubing from disengaging fromreceptacle 14 due to, for example, gravitational forces and/orvibrational stress.

As noted above, the inventive panel 10 may be used in a radiant heatingsystem or in a cooling system where a thermal medium (e.g., water, air)is circulated that transmits heat to the radiant heat transfer plate orthat receives heat from the cooling plate.

Heat transfer within the radiant heating or cooling panel 10 of thepresent invention takes place by both conductance (between the tubingand inner surface of the tubing receptacle 14) and convection (from thetubing through air contained within the depressions 18 and into thetubing receptacle 14 and plate 12). The depressions 18 increase theinner surface area of the tubing receptacle 14 thereby effecting anincrease in overall heat transfer, when compared to a tubing receptaclehaving a smooth inner surface.

The radiant panel 10 of the present invention is preferably constructedfrom a thermally conductive material such as copper or aluminum, and ismore preferably constructed from aluminum. In yet a more preferredembodiment, radiant panel 10 is a unitary or one-piece, extrudedaluminum panel that is prepared by co-extruding plate 12 and tubingreceptacle 14 using conventional extrusion methods and techniques.

Generally speaking, the radiant panel 10 of the present invention may beinstalled by surface mounting or embedding on/in floors, walls, orceilings, and is suitable for use in both wet and dry installations.Installation of the inventive panels 10 together with tubing is astraightforward process, which begins with arriving at a workable designfor the radiant heating or cooling installation. As will be readilyappreciated by those skilled in the art, the design of any suchinstallation is driven by required heating or cooling and performancerequirements. For radiant heating installations, heatloss and heatrequirements for the target area would be calculated; the requiredtemperatures of the thermal medium (e.g., water, air) and floor, wall,or ceiling surfaces would then be determined along with the size andnumber of panels 10, length of tubing, and preferred panel layout.Installation of panels 10 would then proceed by securing the panels 10to target surfaces by hammering or otherwise securing appropriatefasteners such as nails, screws, or construction staples into placethrough, for example, pre-punched mounting holes. A small gap betweenthe ends of adjacent panels 10 in the lengthwise direction would beprovided to allow for expansion and contraction of the panels 10. Oncethe panels are secured in place, the tubing would be installed withintubing receptacles 14. The tubing would be snapped into place,optionally with the aid of, for example, a rubber mallet. No additionalfasteners or supports are needed.

Although the present invention has been shown and described with respectto detailed embodiments thereof, it will be understood by those skilledin the art that various changes in form and detail thereof may be madewithout departing from the spirit and scope of the claimed invention.

1. A radiant heating or cooling panel that comprises: a radiant heattransfer or cooling plate having a length; and an elongated, C-shapedreceptacle for receiving tubing, wherein the elongated, C-shapedreceptacle extends along the length of the radiant heat transfer orcooling plate and is formed from upper and lower arcuate or angledsections, with at least the upper section terminating in an edge,wherein the lower section of the C-shaped receptacle is fixably attachedto the plate along the length of the plate.
 2. The radiant heating orcooling panel of claim 1, which is constructed from a thermallyconductive material.
 3. The radiant heating or cooling panel of claim 2,which is constructed from aluminum.
 4. The radiant heating or coolingpanel of claim 3, which is an extruded, one-piece aluminum panel.
 5. Theradiant heating or cooling panel of claim 1, wherein a plurality ofdepressions extend along a length of an inner surface of the lowersection of the C-shaped receptacle.
 6. The radiant heating or coolingpanel of claim 5, wherein the plurality of depressions comprise two ormore discontinuous depressions.
 7. The radiant heating or cooling panelof claim 5, wherein the plurality of depressions comprise two or morecontinuous depressions that each extend along the entire length of theinner surface of the lower section of the C-shaped receptacle, whereineach continuous depression is contiguous to at least one othercontinuous depression.
 8. The radiant heating or cooling panel of claim7, wherein each depression is a U-shaped depression.
 9. The radiantheating or cooling panel of claim 8, wherein each U-shaped depressionhas a width ranging from about 0.13 to about 0.38 millimeters, and adepth ranging from about 0.25 to about 0.76 millimeters.
 10. The radiantheating or cooling panel of claim 1, wherein both the upper and lowersections of the elongated, C-shaped receptacle terminate in an outwardlyflaring edge.
 11. A radiant heating or cooling panel that comprises: aradiant heat transfer or cooling plate having a length; and anelongated, C-shaped receptacle for receiving tubing, wherein theelongated, C-shaped receptacle extends along the length of the radiantheat transfer or cooling plate and is formed from upper and lowerarcuate or angled sections, wherein the lower section of the C-shapedreceptacle is fixably attached to the plate along the length of theplate, wherein a plurality of depressions extend along an inner surfaceof the lower section of the C-shaped receptacle, wherein the depressionsare selected from the group consisting of: (i) two or more discontinuousdepressions; and (ii) two or more continuous depressions that eachextend along the entire length of the inner surface of the lower sectionof the C-shaped receptacle, wherein each continuous depression iscontiguous to at least one other continuous depression.
 12. A radiantheating or cooling panel that comprises: a radiant heat transfer orcooling plate having a length; and an elongated C-shaped receptacle forreceiving tubing, wherein the elongated C-shaped receptacle extendsalong the length of the radiant heat transfer or cooling plate and isformed from upper and lower arcuate or angled sections, wherein thelower section of the C-shaped receptacle is fixably attached to theplate along the length of the plate, wherein a plurality of depressionsextend along that portion of an inner surface of the lower section ofthe C-shaped receptacle that interfaces with the radiant heat transferor cooling plate.
 13. The radiant heating or cooling panel of claim 12,wherein the plurality of depressions comprise two or more discontinuousdepressions.
 14. The radiant heating or cooling panel of claim 12,wherein the plurality of depressions comprise two or more continuousdepressions that each extend along the entire length of the innersurface of the lower section of the C-shaped receptacle, wherein eachcontinuous depression is contiguous to at least one other continuousdepression.
 15. The radiant heating or cooling panel of claim 14,wherein each depression is a U-shaped depression.